Elastic fiber, elastic fiber covered yarn and reeling manufacturing methods thereof

ABSTRACT

The present disclosure relates to an elastic fiber, an elastic fiber covered yarn and reeling manufacturing methods thereof The reeling manufacturing method of an elastic fiber includes: providing an elastic fiber material, the elastic fiber material having a core portion and a skin portion, the skin portion covering the core portion; performing a first extending, to have the elastic fiber material passing a first guiding roller, the speed of the first guiding roller being 500-1500 m/min; performing a second extending, to have the elastic fiber material passing a second guiding roller, the speed of the second guiding roller being 1200-2400 m/min; and performing a third extending, to have the elastic fiber material passing a third guiding roller, the speed of the third guiding roller is 1300-2600 m/min.

FIELD

The disclosure relates to an elastic fiber, an elastic fiber covered yarn and reeling manufacturing methods thereof

BACKGROUND

In the conventional elastic fiber production process, many reagents are toxic and irritating, especially toluene diisocyanate and 4,4-diphenylmethane diisocyanate. Reagents remaining in elastic fiber textiles may cause allergic reactions. Conventional elastic fibers are difficult to recycle, and may easily produce hydrogen cyanide that pollutes the environment when they are burned. In addition, the conventional elastic fibers have poor light fastness, weather resistance, elongation at break, and deformation rate after stretching, which also affect the service life.

SUMMARY OF THE INVENTION

In accordance with one aspect of the present disclosure, a reeling manufacturing method of an elastic fiber includes: providing an elastic fiber material, the elastic fiber material having a core portion and a skin portion, the skin portion covering the core portion; performing a first extending, to have the elastic fiber material passing a first guiding roller, the speed of the first guiding roller being 500-1500 m/min; performing a second extending, to have the elastic fiber material passing a second guiding roller, the speed of the second guiding roller being 1200-2400 m/min; and performing a third extending, to have the elastic fiber material passing a third guiding roller, the speed of the third guiding roller is 1300-2600 m/min.

In accordance with one aspect of the present disclosure, an elastic fiber, manufactured according to the above reeling manufacturing method, includes a core portion and a skin portion. The skin portion covers the core portion. The linear density of the elastic fiber is 50-300 denier, and elongation at break is 200-400%.

In accordance with one aspect of the present disclosure, a reeling manufacturing method of an elastic fiber covered yarn includes: providing an elastic fiber covered yarn material, the elastic fiber covered yarn material having an elastic fiber and a plurality of peripheral fibers, the plurality of peripheral fibers surrounding the elastic fiber; performing a first extending, to have the elastic fiber covered yarn material passing a first guiding roller, the speed of the first guiding roller being 2000-4500 m/min; and performing a second extending, to have the elastic fiber covered yarn material passing a second guiding roller, the speed of the second guiding roller being 2500-4500 m/min.

In accordance with one aspect of the present disclosure, an elastic fiber covered yarn, manufactured according to the above reeling manufacturing method, includes an elastic fiber; and a plurality of peripheral fibers. The peripheral fibers surround the elastic fiber. The linear density of the elastic fiber covered yarn is 50-300 denier, and elongation at break is 20-150%.

BRIEF DESCRIPTION OF THE DRAWINGS

Aspects of the present disclosure are understood from the following detailed description when read with the accompanying figures. It is emphasized that, in accordance with the standard practice in the industry, various features are not drawn to scale. In fact, the dimensions of the various features may be arbitrarily increased or reduced for clarity of discussion.

FIG. 1 shows a flowchart of a reeling manufacturing method of an elastic fiber according to an embodiment of the present disclosure.

FIG. 2 shows a flowchart of a reeling manufacturing method of an elastic fiber covered yarn according to another embodiment of the present disclosure.

DETAILED DESCRIPTION OF THE INVENTION

It is to be understood that the following disclosure provides many different embodiments or examples, for implementing different features of various embodiments. Specific examples of components and arrangements are described below to simplify the present disclosure. The present disclosure may, however, be embodied in many different forms and should not be construed as being limited to the embodiments set forth herein; rather, these embodiments are provided so that this description will be thorough and complete, and will fully convey the present disclosure to those of ordinary skill in the art. It will be apparent, however, that one or more embodiments may be practiced without these specific details.

In addition, the present disclosure may repeat reference numerals and/or letters in the various examples. This repetition is for the purpose of simplicity and clarity and does not in itself dictate a relationship between the various embodiments and/or configurations discussed.

It will be understood that when an element is referred to as being “on” another element, it can be directly on the other element or intervening elements may be present. In contrast, when an element is referred to as being “directly on” another element, there are no intervening elements present.

It will be understood that singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise.

Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure belongs. It will be further understood that terms; such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and the present disclosure, and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.

FIG. 1 shows a flowchart of a reeling manufacturing method of an elastic fiber according to an embodiment of the present disclosure.

With reference to FIG. 1 , referring to step S11 first, an elastic fiber material is provided. The elastic fiber material has a core portion and a skin portion. The skin portion covers the core portion. The radius ratio of the core portion to the skin portion is 1:9 to 9:1. In an embodiment, the reeling temperature of the elastic fiber material may be 160-240° C. In an embodiment, the reeling temperature of the elastic fiber material may be 180-220° C.

Referring to step S12, a first extending is performed. The elastic fiber material passes a first guiding roller. The speed of the first guiding roller is 500-1500 m/min. In an embodiment, the first guiding roller may have an upper roller and a lower roller that are symmetrical, and the elastic fiber material runs between the two symmetrical rollers to realize the extending. In an embodiment, the speed of the first guiding roller is 550-1300 m/min. In an embodiment, the temperature of the first guiding roller is 10-75° C. In an embodiment, the temperature of the first guiding roller is 15-60° C.

Referring to step S13, a second extending is performed. The elastic fiber material passes a second guiding roller. The speed of the second guiding roller is 1200-2400 m/min. In an embodiment, the second guiding roller may have an upper roller and a lower roller that are symmetrical, and the elastic fiber material runs between the two symmetrical rollers to realize the extending. In an embodiment, the speed of the second guiding roller is 1300-2000 m/min. In an embodiment, the temperature of the second guiding roller is 10-75° C. In an embodiment, the temperature of the second guiding roller is 15-60° C. In an embodiment, the speed of the second guiding roller may be higher than the speed of the first guiding roller.

Referring to step S14, a third extending is performed. The elastic fiber material passes a third guiding roller. The speed of the third guiding roller is 1300-2600 m/min. In an embodiment, the third guiding roller may have an upper roller and a lower roller that are symmetrical, and the elastic fiber material runs between the two symmetrical rollers to realize the extending. In an embodiment, the speed of the third guiding roller is 1350-2500 m/min. In an embodiment, the temperature of the third guiding roller is 10-75° C. In an embodiment, the temperature of the third guiding roller is 15-60° C. In an embodiment, the speed of the third guiding roller may be higher than the speed of the second guiding roller. In an embodiment, the speed is the peripheral speed of the guiding roller.

In an embodiment, after the third extending step, the method further includes a winding step. The elastic fiber material passes a winding roller for winding. The speed of the winding roller is 1250-2250 m/min. In an embodiment, the speed of the winding roller is 1450-2150 m/min. In an embodiment, the speed of the winding roller may be lower than the speed of the third guiding roller.

The present disclosure provides an elastic fiber, which is manufactured by the reeling manufacturing method as described above. In an embodiment, the elastic fiber includes a core portion and a skin portion. The skin portion covers the core portion. The linear density of the elastic fiber is 50-300 denier, and the elongation at break is 200-400%. In an embodiment, the elongation at break is 250%-350%. In an embodiment, the material of the core portion may be thermoplastic polyurethane (TPU). In an embodiment, the material of the skin portion may be a TPU fiber, a polyester fiber or a nylon fiber, but not limited thereto.

In an embodiment, after the elastic fiber is stretched by 30-250%, the deformation rate is 0-30%. Therefore, after the elastic fiber of the present disclosure is stretched, the deformation rate is quite small, which can prolong the service life. In an embodiment, the hardness of the elastic fiber is Shore 80A to Shore 80D. In an embodiment, the hardness of the elastic fiber is Shore 80A to Shore 75D. In an embodiment, the hardness of the elastic fiber is Shore 80A to Shore 70D.

Therefore, according to the reeling manufacturing method of the elastic fiber of the present disclosure, after the elastic fiber of the present disclosure is stretched, the deformation rate is quite small, which can prolong the service life. In addition, due to the high recyclability of TPU, the elastic fiber of the present disclosure can be recycled and granulated after being used, and thus has environmental protection benefit. Moreover, the TPU recycled particles obtained after recycling and granulation may be added to the manufacturing process of the elastic fiber of the present disclosure to further enhance the environmental protection benefit, thereby saving the manufacturing cost. In addition, the reeling manufacturing method of the elastic fiber of the present disclosure is simple, and the cost of the TPU elastic fiber material is lower than that of the conventional LYCRA elastic fiber.

FIG. 2 shows a flowchart of a reeling manufacturing method of an elastic fiber covered yarn according to another embodiment of the present disclosure. With reference to FIG. 2 , referring to step S21 first, an elastic fiber covered yarn material is provided. The elastic fiber covered yarn material has an elastic fiber and a plurality of peripheral fibers. The plurality of peripheral fibers surround the elastic fiber. In an embodiment, the elastic fiber may be the elastic fiber described above, which will not be described in detail here. In an embodiment, the plurality of peripheral fibers contact the elastic fiber together through a plurality of spray nodes. The elasticity of each of the peripheral fibers may be lower than that of the elastic fiber.

In an embodiment, the routine material of the plurality of peripheral fibers includes polyethylene terephthalate, polybutylene terephthalate, nylon 6 or nylon 66, but not limited thereto. The material of the plurality of peripheral fibers further includes a recycled material. The routine material and the recycled material of the plurality of peripheral fibers are mixed at a weight ratio of 55%:45% to 100%:0%. In an embodiment, the routine material and the recycled material of the plurality of peripheral fibers are mixed at a weight ratio of 60%:40% to 90%:10%. In an embodiment, the routine material and the recycled material of the plurality of peripheral fibers are mixed at a weight ratio of 70%:30% to 85%:15%. In an embodiment, due to the high recyclability of TPU, the elastic fiber of the present disclosure can be recycled and granulated as the recycled material after being used. The recycling and granulation temperature is 240-320° C. In an embodiment, the recycling and granulation temperature is 280-300° C.

In an embodiment, the manner in which the plurality of peripheral fibers surround the elastic fiber includes a Single Covered Yarn (SCY), a Double Covered Yarn (DCY), an Air-Jet Covered Yarn (ACY) or an Air textured Yarn (ATY), but not limited thereto.

In an embodiment, the reeling temperature of the elastic fiber covered yarn material may be 240-320° C. In an embodiment, the reeling temperature of the elastic fiber covered yarn material may be 280-300° C.

Referring to step S22, a first extending is performed. The elastic fiber covered yarn material passes a first guiding roller. The speed of the first guiding roller is 2000-4500 m/min. In an embodiment, the first guiding roller may have an upper roller and a lower roller that are symmetrical, and the elastic fiber covered yarn material runs between the two symmetrical rollers to realize the extending. In an embodiment, the speed of the first guiding roller is 2500-4500 m/min. In an embodiment, the temperature of the first guiding roller is 10-75° C. In an embodiment, the temperature of the first guiding roller is 15-60° C.

Referring to step S23, a second extending is performed. The elastic fiber covered yarn material passes a second guiding roller. The speed of the second guiding roller is 2500-4500 m/min. In an embodiment, the second guiding roller may have an upper roller and a lower roller that are symmetrical, and the elastic fiber material runs between the two symmetrical rollers to realize the extending. In an embodiment, the speed of the second guiding roller is 3000-4000 m/min. In an embodiment, the temperature of the second guiding roller is 10-75° C. In an embodiment, the temperature of the second guiding roller is 15-60° C. In an embodiment, the speed of the second guiding roller may be higher than the speed of the first guiding roller.

In an embodiment, after the second extending step, the method further includes a winding step. The elastic fiber material passes a winding roller for winding. The speed of the winding roller is 2500-5000 m/min. In an embodiment, the speed of the winding roller is 3000-5000 m/min. In an embodiment, the speed of the winding roller may be higher than the speed of the second guiding roller.

The present disclosure provides an elastic fiber covered yarn, which is manufactured by the reeling manufacturing method as described above. In an embodiment, the elastic fiber covered yarn includes an elastic fiber and a plurality of peripheral fibers. The plurality of peripheral fibers surround the elastic fiber. The linear density of the elastic fiber covered yarn is 50-300 denier, and the elongation at break is 20-150%. In an embodiment, the elongation at break is 30%-120%.

Therefore, according to the reeling manufacturing method of the elastic fiber covered yarn of the present disclosure, the elongation at break of the elastic fiber covered yarn of the present disclosure is relatively good. In addition, due to the high recyclability of TPU, the elastic fiber of the present disclosure can be recycled and granulated after being used, and thus has environmental protection benefit. Moreover, the TPU recycled particles obtained after recycling and granulation may be added to the manufacturing process of the elastic fiber covered yarn of the present disclosure to further enhance the environmental protection benefit, thereby saving the manufacturing cost. In addition, the reeling manufacturing method of the elastic fiber covered yarn of the present disclosure is simple, and the cost of the TPU elastic fiber material is lower than that of the conventional LYCRA elastic fiber.

Embodiment 1

A TPU elastic fiber material was used. The material of a core portion was TPU, and the material of a skin portion was TPU. The reeling temperature of the TPU elastic fiber material was 190° C.

Extending of the TPU elastic fiber included steps as follows. A first extending was performed. The elastic fiber material passed a first guiding roller. The speed of the first guiding roller was 550 m/min. The temperature of the first guiding roller was 60° C. A second extending was performed. The elastic fiber material passed a second guiding roller. The speed of the second guiding roller was 1200 m/min. The temperature of the second guiding roller was 55° C. A third extending was performed. The elastic fiber material passed a third guiding roller. The speed of the third guiding roller was 1650 m/min. The temperature of the third guiding roller was 55° C. The TPU elastic fiber was wound at a speed of 1550 m/min.

It was tested that the linear density of the TPU elastic fiber was 50-300 denier, and the elongation at break was 200-400%. After the TPU elastic fiber was stretched by 30-250%, the deformation rate was 0-30%. According to DINISO7619-1, the hardness of the TPU elastic fiber was measured to be Shore 95A.

Embodiment 2

The TPU elastic fiber was recycled and granulated to obtain TPU recycled particles. The TPU recycled particles were added to the routine material of a plurality of peripheral fibers. The reeling temperature of the elastic fiber covered yarn material was 240° C.

Extending of the TPU elastic fiber covered yarn included steps as follows. A first extending was performed. The elastic fiber covered yarn material passed a first guiding roller. The speed of the first guiding roller was 2600 m/min. The temperature of the first guiding roller was 50° C. A second extending was performed. The elastic fiber covered yam material passed a second guiding roller. The speed of the second guiding roller was 3500 m/min. The temperature of the second guiding roller was 50° C. The TPU elastic fiber covered yarn was wound at a speed of 3000 m/min.

It was tested that the linear density of the TPU elastic fiber covered yarn was 50-300 denier, and the elongation at break was 20-150%.

Moreover, the scope of the present application is not intended to be limited to the particular embodiments of the process, machine, manufacture, and composition of matter, means, methods and steps described in the specification. As those skilled in the art will readily appreciate form the present disclosure, processes, machines, manufacture, compositions of matter, means, methods, or steps, presently existing or later to be developed, that perform substantially the same function or achieve substantially the same result as the corresponding embodiments described herein may be utilized in accordance with some embodiments of the present disclosure.

Accordingly, the appended claims are intended to include within their scope such processes, machines, manufacture, and compositions of matter, means, methods or steps. In addition, each claim constitutes a separate embodiment, and the combination of various claims and embodiments are within the scope of the disclosure. 

What is claimed is:
 1. A reeling manufacturing method of an elastic fiber, comprising: providing an elastic fiber material, the elastic fiber material having a core portion and a skin portion, the skin portion covering the core portion; performing a first extending, to have the elastic fiber material passing a first guiding roller, the speed of the first guiding roller being 500-1500 m/min; performing a second extending, to have the elastic fiber material passing a second guiding roller, the speed of the second guiding roller being 1200-2400 m/min; and performing a third extending, to have the elastic fiber material passing a third guiding roller, the speed of the third guiding roller is 1300-2600 m/min.
 2. The reeling manufacturing method of claim 1, wherein the speed of the first guiding roller is 550-1300 m/min, the speed of the second guiding roller is 1300-2000 m/min, the speed of the third guiding roller is 1350-2500 m/min.
 3. The reeling manufacturing method of claim 1, wherein further includes a winding step, to have the elastic fiber material passing a winding roller for winding, the speed of the winding roller being 1250-2250 m/min.
 4. The reeling manufacturing method of claim 1, wherein the reeling temperature of the elastic fiber material may be 160-240° C.
 5. The reeling manufacturing method of claim 1, wherein the temperature of the first guiding roller is 10-75° C., the temperature of the second guiding roller is 10-75° C., the temperature of the third guiding roller is 10-75° C.
 6. An elastic fiber, manufactured according to the reeling manufacturing method of claim 1, comprising: a core portion; and a skin portion, covering the core portion; wherein linear density of the elastic fiber is 50-300 denier, and elongation at break is 200-400%.
 7. The elastic fiber of claim 6, wherein the elongation at break is 250%-350%.
 8. The elastic fiber of claim 6, wherein after the elastic fiber is stretched by 30-250%, the deformation rate is 0-30%.
 9. A reeling manufacturing method of an elastic fiber covered yarn, comprising: providing an elastic fiber covered yarn material, the elastic fiber covered yarn material having an elastic fiber and a plurality of peripheral fibers, the plurality of peripheral fibers surrounding the elastic fiber; performing a first extending, to have the elastic fiber covered yarn material passing a first guiding roller, the speed of the first guiding roller being 2000-4500 m/min; and performing a second extending, to have the elastic fiber covered yarn material passing a second guiding roller, the speed of the second guiding roller being 2500-4500 m/min.
 10. The reeling manufacturing method of claim 9, wherein the speed of the first guiding roller is 2500-4500 m/min, the speed of the second guiding roller is 3000-4000 m/min.
 11. The reeling manufacturing method of claim 9, wherein further comprising a winding step, to have the elastic fiber material passing a winding roller for winding, the speed of the winding roller is 2500-5000 m/min.
 12. The reeling manufacturing method of claim 9, wherein the reeling temperature of the elastic fiber covered yarn material is 240-320° C.
 13. The reeling manufacturing method of claim 9, wherein the temperature of the first guiding roller is 10-75° C., and the temperature of the second guiding roller is 10-75° C.
 14. The reeling manufacturing method of claim 9, wherein routine material of the plurality of peripheral fibers comprises polyethylene terephthalate, polybutylene terephthalate, nylon 6 or nylon 66
 15. The reeling manufacturing method of claim 14, wherein material of the plurality of peripheral fibers further comprises a recycled material.
 16. The reeling manufacturing method of claim 15, wherein the routine material and the recycled material of the plurality of peripheral fibers are mixed at a weight ratio of 55%:45% to 100%:0%.
 17. The manufacturing method of claim 9, wherein manner in which the plurality of peripheral fibers surround the elastic fiber comprises a Single Covered Yam (SCY), a Double Covered Yarn (DCY), an Air-Jet Covered Yarn (ACY) or an Air textured Yarn (ATY). 